Pin studded punch roll including method of fabrication



Feb. 20, 1962 M, o, sc u 3,021,732

PIN STUDDED PUNCH ROLL INCLUDING METHOD OF FABRICATION Filed Dec. 18, 1959 3 Sheets-Sheet 1 INVENT MILTON O. SCH

mm-04a eb- 20, 196 M. o. SCHUR 3,021,732

PIN STUDDED PUNCH ROLL INCLUDING METHOD OF FABRICATION Filed Dec. 18, 1959 3 Sheets-Sheet 2 INVENTOR. FIG 5 MILTON o. SCHUR M. o. SCHUR 3,021,732 PIN STUDDED PUNCH ROLL INCLUDING METHOD OF FABRICATION Feb. 20, 1962 3 Sheets-Sheet 3 Filed Dec. 18, 1959 FIG FIG-8 INVENTOR. MILTON O. SCHUR 3,021,732 7 PIN STUDDED PUNCH ROLL INCLUDING METHOD OF FABRICATION Milton 0. Schur, Asheville, N.C., assignor to Olin Matine- -son Chemical Corporation,

Filed Dec. 18, 1959, Ser. No. 860,513

4 Claims. (Cl. 76-101) The present invention relates to web perforating and,

in particular, relates to a web perforating roll including a method of fabricating the roll. A particular feature of the invention is the provision of a novel punch oripin studded web perforating roll. The term punch as utilized here is intended to refer to small pins or a rod-like structure having diameters as small as 2 to 3 thousandths of an inch.

A further feature of the invention is the provision of anovel method'of fabricating aweb perforating roll.-

A further feature of the invention is the provision of a web roll .of the above class which is easily kept in prime condition operative to cut or pierce clean perforations in a continuously advancing sheet or web with a minimum of expense and labor;

A further feature of the invention resides in the fact that the novel process disclosed presents a very convenient and simple methodfor sharpening a plurality of punches simultaneously and in situ where the punches are studded about a roll in circumferential array.

A process embracing certain features of the present invention may comprise a plurality of apertured discs or washers, winding a portion of the washers in toroidal fashion with a wire strand or metal filament while a portion of the washers remain blank or free of a winding, dipping the wound washers in a resin or wax solution effective to coat or mask the wire and the washers with the solution, assembling a plurality of blank and Wound washers upon a mandrel to form a generally cylindrical roll so that the roll is formed compositely of blank washers and wound washers, removing a portion of the exterior surface of the roll effective to reduce the outer diameter thereof and effective to cut the wire strands and etching the discs so as to remove a circumferential margin thereof whereby a plurality of segments of Wire project radially from the roll and in circumferential array about-the exterior surface of the roll.

. An apparatus embracing certain features of the present invention may comprise a generally cylindrical laminated roll, said roll being fabricated compositely of a plurality of discs or washers each having a bore and bound together in side by-side relationship by suitable clamp means received in the bores, a plurality of radially projecting pins disposed between the discs arranged in circumferential array and projecting beyond the cylindrical surface of the roll, said pins being coated with a resinous or waxy material in the region thereof received between the washers and said washers and said pins, respectively, being fabricated of metallic materials having diverse positions in the electromotive series.

Other features and advantages of the present invention will become more apparent from the succeeding specification .when read in conjunction with the appended drawings, in which:

FIG. 1 is a disclosure of an apparatus embracing the principles of the present invention;

FIG. 2 is a plan view' of a portion of the apparatus of FIG. 1;

1 FIG. 3 is an elevational view of a serrated or notched washer; FIG. 4 is an elevational view of a plain or blank washer;

FIG. 5 is a view of a portion ofthe washer of FIG.

a corporation of Virginia closed embodiment of the ing process will etch or 3,021,732 Patented Feb. 20, 1962 2 3, somewhat enlarged, showing the washer served or wound toroidally by a wire strand or metal filament;

FIG. 6 shows an assembly of blank washers and wire wound washers combined into aunit to define a laminated roll; I

FIG. 7 shows a portion of the exterior surface of the punch roll, somewhat enlarged for clarity, as it appears after grinding; and,

FIG. 8 is an elevational view, somewhat enlarged, of a portion of the pin studded web perforating roll of FIG. 1, broken away for clarity, showing the composite structure of the roll and the disposition and conformation of the pin-like punches which project beyond the cylindrical surface of the roll.

Referring now in detail to the drawings, there is shown in FIG. 1 a typical arrangement in which the web perorati'ng roll, fabricated in accordance with the present invention, may be utilized. The arrangement shown comprises a supply roll of web or sheet material S continuously advancing in the direction of the arrow to a take-up or rewind rollT. The web material advances between an idler roll U and a sand paper or abrasive roll V. The web is guided further by the flanged pin G-G. Head roll H is provided in conventional fashion to insure a tight uniform package at the rewind end.

Mounted over the supply roll S and free to pivot or move in the fashion of a universal joint is a pin studded punch roll indicated generally by the reference-numeral,

10. As is more apparent in FIG. 2, the roll is supported by means of appropriate bearings upon an axle or shaft 11 received in a generally C-shaped yoke 12 in turn pivotally mounted in a bifurcated rod 13 received within a support arm 14 in telescopic fashion. Note that the rod 13 is restrained by suitable means .from moving relative to the arm 14 in an axial direction but is free to rotate relative thereto about a longitudinal axis common to both elements. The arm 14 is pivotally mounted toa fixed bearing as at 16.

As a result ofthis manner of mounting the pin studded perforating roll 10, the roll is free to follow the supply roll S quite closely in that the roll can readily move upwardly and downwardly as shown by the arrows 17 of FIG. 1 and laterally to and fro in the direction shown by, the arrows of FIG. 2. The roll 10 is also free to rotate relative to the arm I4 as previously described.

Referring now to the scheme for fabricating the dispin studded roll, one must provide, basically, a plurality of metallic washers 18 (FIG. 4) and a quantity of metallic strands or Wire 20 (FIG. 5) Where the wire and the washers are fabricated of metals which are disposed in diverse positions in the electromotive series so that an electrolytic bath or etcherode one metal or the other, selectively.

At, this point, it is appropriate to state that although the present invention may be practiced with any size wire or any size washer, it is noteworthy that the invention is singularly useful where there is a requirement for a roll studded with a plurality of exceedingly small punches or pins having a diameter of the order of 2 to 3 thousandths of an inch and projecting radially a distance of the order of 5 to 6 thousandths of an inch.

Obviously, in such a roll, the wire utilized would correspondingly have a diameter of the order of 2 to 3 thousandths of an inch. In the disclosed embodiment, the washers are fabricated of aluminum and the Wire of steel and an etching bath comprising a 10% solution of sodium hydroxide maintained at 40 C. is utilized because it is desired to remove or etch the aluminum. Consequently, a plurality of washers 18 fabricated of aluminum and having a central aperture 19, hereinafter referred to as blank washers, are provided.

Approximately /2 of a given group of washers are machined by an appropriate method, such as grinding or milling to develop a plurality of generally V-shaped notches 21 upon the exterior of the washer and uniformly spaced in circumferential array as shown in FIG. 3. A corresponding number ofnotches 22 are machined upon the interior of the surface of the same washers arranged so that a given pair of notches 21'22 fall upon or are common to a given radius R. For purposes of clarity in describing the invention, the plain or blank washer may be identified hereinafter by the reference numeral 18 while the notched washers will be identified by the reference numeral 23.

After notching, the washers 23" are' then served or wound with wire 20 in toroidal fashion so that the wire encircles the hat of the washer and engages the grooves 21 and 22 in sequence as shown in FIG. Obviously the wire may be applied with any desired lead or helix angle, however, it is preferred that the radial position of the wire in" the" region of the sides or faces 24 of the washers correspond as much as possible to thedisposition of a radius line R. In the'prcsent disclosure the wire is of steel and has a diameter of about 7 of an inch. The lead angle is developed by winding the wire so that it is lead from a notch 22 falling on radius R, for example, to a' notch 21 falling on an adjacent radius such as R (FIG43).

In addition, it is necessary to secure the extremities of the wire (usually a single length of wire is utilized) on the sides of the washer 23 to prevent unwinding by any appropriate scheme such as welding, soldering, or the like.

After the washers 23 are wound they are immersed 4: an appropriate etching bath as shown at in FIG. 6 for the purpose of selectively etching the roll. As stated previously, the bath of the present embodiment is made up of a 10% solution of sodium hydroxide held at about C.

Upon rotating the rollin the bath, electrolytic action occurs effective to erode or remove by electrolysis a definite annular margin of each aluminum disc 18 or 23, as the case may be, with the resultthat a definite segment of wire projects (in. the. present. embodiment the wire projects about $5 Ofi an inch) beyond the surface of the roll thus defining a plurality of radially disposed, uniformly spaced array of pins or punches. identified'by the reference numeral 31 in FIG. 8

Next an appropriate brush or similar tool is utilized t owipe or sweep the webs of resinous material identitied in FIG. 8 by the reference numeral 32' from between the'various pins or punches 31' to generate a clean pin studded roll as shown at 33' on the right hand side of FIG. 8.

As stated previously, it is notintended 'that the process be limited to the particular metals disclosed so long as the metals may be selectively etched.

Among the advantages residing in the punch r'oll of the presentinvention are the following:

(l) The roll may be readilyresharPened by merely taking an additional cut from the exterior surface of the roll utilizing a grinding wheel or the likeaspreviously described to remove dull pins and thereafter etching thecomposite roll todevelop new segments of wire 33 operative to perforate or pierce acontinuously advancing web in the manner previously described;

ina bath of masking material such" as resin or wax for the purpose of coating the exposed surfaces of the washer 23 and the wire with a protective skin; A preferred masking bath may comprise a solution of 50% medium molecular weight polyethylene and 50% paraffin wax suitably heated to a' fluid state;

After the masking step, a plurality of wound washers 23 and blank washers '18 are assembled in face to face relationship upon a mandrel or rod, such as the axle 11-, shown in FIG. 6. The blank washers and the wire Wound washers are disposed alternately and are squeezed tightly together axially by suitably setting up the nut 26 threadedly engaging the axle 11 as at 27. With the blank and wound discs thus arranged, a composite roll is formed wherein blank washers of aluminum are disposed on either side of aluminum washers wound with steel wire so' that most of the wire and resinous material is sandwiched between washers.

The next process step involves removing a portion of the exterior surface of the composite roll; and, in the disclosed embodiment of the invention, a grinding wheel 28 is utilized to take a uniform cut from the exterior surface of the roll efiective to remove the" notches 21 continuously advancing web and to cut that portion of the wire 20 which was disposed in the notches 21.

Aiter the grinding operation the exterior surface of the roll presents the appearance shown most clearly in FIG; 7 wherein one may observe a plurality of discs of aluminum having sandwiched therebetween radially projecting lengths of wire uniformly spaced and disposed in circumferential array, each having a flat head or face identified by the reference numeral 29 and having a diameter of about yi of an inch corresponding to the diameter of the wire with which the discs 23 were wound. Note, too, that the space between adjac'ent discs not occupied by wire strands in filled with: resin or masking material wherein the axial squeeze of the discs upon assembly of the roll was effective to extrude the resin in the interstices between wires as is apparent in FIG; 7..

The next process step embraces immersing a marginal portion of the exterior cylindrical surface of the roll: in

. Frequently it is (2') The punch roll fabricated according to the disclosed process is veryeconomical andthe-nature of the process permits one to grind an exceedingly flat sur face upon the projecting endof eachwire 20 allowing a very sharp corner between the plane oftbe fa'ce -ofi each wire and the longitudinal axis thereof.-

A preferred arrangement for mounting a pin studded punch roll manufactured in accordance with the present invention with respect to a continuously advancing'web of. sheet material is shown in FIG. 1. As stated previously, in thisfigure there-is shown a punch studded roll indicated generally by the reference numeral 10 mounted immediately over a supply roll S.

Note that the punch roll is so mounted that the supply roll operates as an anvil sothat, in effect; the of material is perforated before it leaves the roll. The thickness of the web being perforated is frequently of a very small dimension (ranging from the order 0t 1 of an inch to of an inch) and should the punches penetrate through more than one thickness of the web while upon" the supply'rollthe perforations sofor'med create a random pattern;

desirable to utilize light sanding rolls. to clean up the paper surface by wiping on loose chads or particles of paper after perforation.

Obviously a variety ofarrangements' of the present invention may be devised both in the process and" apparatus embodiments thereof without departing from the. spirit and scope of the invention;

What is claimed is:

1; A method of fabricating a pin studded web per,- forating roll comprising the steps of providing a plurality of metal washers or apertnred discs, providing a quantityof metallic strand material, assembling the discs and the strand material on a mandrel to form a roll wherethe roll is formed compositel'y of metal strands sandwiched between discs in alternating fashion, said metallic strands being'disposed radially so as to project toward the exterior of the roll and selectively dissolving portions of the-roll effective to expos'e a-- circumferential array of pins projecting radially from-the roll. 7

2-. Amcthodof fabricatinga pin studded web perforating roll comprising the steps of providing a plurality of washers or apertured discs, machining circumferentially disposed grooves in some of the discs about the external and internal margins thereof, winding the grooved discs in toroidal fashion with a wire filament so that the wire encircles the disc with the wire filament disposed in the grooves, dipping the wound disc in a masking solution effective to coat the wire and the disc uniformly, assembling a plurality of wound and unwound discs on a mandrel to form a roll where the roll is formed compositely of unwound discs and wound discs arranged in alternating fashion, squeezing the compositely arranged discs together axially effective to combine the discs in a compact mass, removing a portion of the exterior surface of the roll efiective to reduce the exterior diameter thereof and effective to cut the wire strands and selectively removing a circumferential margin of the roll effective to expose and array of pins projecting radially from the roll.

3. A method of fabricating a pin studded web perforating r011 comprising the steps of providing a plurality of Washers or apertured discs, winding the discs in toroidal fashion with a Wire filament so that the wire encircles the disc, assembling a plurality of wound and unwound discs on a mandrel to form a roll where the roll is formed compositely of unwound discs and wound discs arranged in alternating fashion, removing a portion of the exterior surface of the roll eifective to reduce the exterior diameter thereof and effective to cut the wire strands and selectively removing a circumferential margin of each disc eifective to expose a circumferential array of pin-like protuberances projecting radially from the roll.

4. The method of claim 2 wherein the masking material is swept away after the margin of the roll is removed.

References Cited in the file of this patent UNITED STATES PATENTS 704,789 Elson July 15, 1902 1,904,100 Taylor Apr. 18, 1933 1,958,694 Chandler May 15, 1934 1,975,487 Topping Oct. 2, 1934 2,101,753 Rambold Dec. 7, 1937 2,455,348 Barstow Dec. 7, 1948 2,518,838 Tempe Aug. 15, 1950 2,667,090 Martin Jan. 26, 1954 

